Swiss cheese attachment

ABSTRACT

A two-piece part may include a first portion defining at least one through hole and a second portion may be cast such that the second portion extends through the through hole thereby mechanically interlocking the first portion and the second portion together.

TECHNICAL FIELD

The field to which the disclosure generally relates includes two-partpolymer products being mechanically bonded together and methods ofproducing the same.

BACKGROUND

Multi-shot injection molding or over-molding is typically restricted tothe use of two or more polymer materials known to chemically bondtogether. Such methods often require very narrow process parameters.Tearing or separation of the two or more materials at an interface mayoccur if process parameters are not followed carefully.

SUMMARY OF ILLUSTRATIVE VARIATIONS OF THE INVENTION

According to one variation, a method may provide a first part that mayinclude a first material that may define a plurality of through holes.The first part may be formed or placed in a mold, and a second materialmay be caused to flow over the first part and through the through holesof the first part. When cooled, the second material may form a secondpart that may be mechanically bonded to the first part via portions ofthe second part that may extend through or around the first part.

A second variation may include a first portion that may include a firstmaterial composition and a second portion that may include a secondcomposition. The first portion may define a plurality of through holesand the second portion may extend through said through holes. Theextension of the second portion through the through holes of the firstportion and the through holes themselves may be constructed and arrangedto facilitate an interlocking mechanical bond between the first portionand the second portion.

Other illustrative variations of the invention will become apparent fromthe detailed description provided hereinafter. It should be understoodthat the detailed description and enumerated variations, whiledisclosing optional variations of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Select examples of variations of the invention will become more fullyunderstood from the detailed description and the accompanying drawings,wherein:

FIG. 1 illustrates a swiss cheese attachment according to one variationof the invention; and

FIG. 2 illustrates a Swiss cheese attachment according to one variationof the invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE VARIATIONS OF THE INVENTION

The following description of the variations is merely illustrative innature and is in no way intended to limit the scope of the invention,its application or uses. The following description of variants is onlyillustrative of components, elements, acts, products, and methodsconsidered to be within the scope of the invention and are not in anyway intended to limit such scope by what is specifically disclosed ornot expressly set forth. The components, elements, acts, products, andmethods as described herein may be combined and rearranged other than asexpressly described herein and still are considered to be within thescope of the invention.

Referring to FIG. 1; a Swiss cheese attachment 10 may include a firstportion 12. The first portion 12 may define at least one through whole14.

Referring to FIG. 2; a Swiss cheese attachment 10 may include a firstportion 12. The first portion 12 may define at least one through hole 14and may comprise at least one grate 16. The at least one grate 16 may belocated within the at least one through hole 14.

The first portion may be a part for use in an automobile, aircraft,watercraft, or any vehicle or application where parts includingdissimilar materials are utilized. The first portion may be a hardplastic molded via an injection molding process or as a first portionmolded in a two-shot injection molding process, or in an over moldinjection process. In a number of variations the hardness of the firstportion may range from about 100 MPa to about 2500 MPa. The firstportion may define at least one through hole within a body of the firstportion. The at least one through hole may be formed at the same timethat the part is formed. Alternatively, the at least one through holemay be formed as part of secondary or post-processing operations or byany other suitable means known in the art. In a number of variations,suitable materials for the first portion may include, but are notlimited to, styrenics, acetal, thermoplastic polyolefin (TPO),thermoplastic polyurethanes (TPU), polycarbonates, acrylics, nylons,polyethylene, polyesters, thermoset composites, poly vinyl chlorides,and/or ionomers.

The at least one through hole may be of any cross-sectional shape orconfiguration desired. The at least one through hole may range incross-sectional area from about macroscopic to about microscopic toabout nanoscopic in size. In a number of variations, the holes may havea diameter ranging from about 1/16 inch to 1 inch, or for squares orrectangular holes having dimensions ranging from about 1/16 inch by 1/16inch by 1/16 inch to about 1 inch by 1 inch by 1 inch, or for hole ofother shapes the hole may be of an area ranging from 0.0039 to 1 squareinches.

The second portion may be a part for use in an automobile, aircraft,watercraft, or any vehicle or application where parts includingdissimilar materials are utilized. The second portion may be a softpolymer molded via an injection molding process. In a number ofvariations the hardness of the second portion may range from about 15Shore A to about 95 Shore D. The second portion may extend through theat least one through hole within a body of the first portion. In anumber of variations suitable materials for the second portion include,but are not limited to, thermoplastic elastomers (TPE), thermoplasticvulcanite, thermoplastic polyolefin (TPO), polyvinyl chlorines, and/orthermoplastic polyurethanes.

The grate may be constructed and arranged to facilitate the interlockingmechanical bond of the first portion and the second portion byincreasing the amount of surface contact between the first portion andthe second portion. The grate may define a plurality of openings, andthe cross-sectional area of the openings may range from aboutmacroscopic to about microscopic to about nanoscopic in size. In anumber of variations the grate may include a plurality of horizontal andvertical bars or rods made from fiber, polymer, or metal such as wire.

According to a first variation, a product may include a first portionthat may include a first composition and may be constructed and arrangedto define at least one through hole in the first portion. The productmay also include a second portion that may include a second compositionand may be constructed and arranged to extend through the at least onethrough hole of the first portion such that the first portion and thesecond portion may form an interlocking mechanical bond.

A second variation may include a product as set forth in the firstvariation wherein the cross-sectional area of the at least one throughhole may range from about macroscopic to about microscopic to aboutnanoscopic in size.

A third variation may include a product as set forth in the first orsecond variations where the first composition of the first portion maybe capable of chemically bonding to the second composition of the secondportion.

A fourth variation may include a product as set forth in the firstthrough second variations where the composition of the first portion maybe incapable of chemically bonding to the composition of the secondportion.

A fifth variation may include a product as set forth in the firstthrough fourth variations where the first portion may additionallyinclude at least one grate and where the at least one grate may bedisposed within the at least one through hole of the first portion. Thegrate portion may be constructed and arranged to further facilitate theinterlocking mechanical bond of the first portion and the secondportion.

A sixth variation may include a product as set forth in the firstthrough fifth variations where the first portion may be a hard polymerand the second portion may be a soft polymer.

A seventh variation may include a product as set forth in the fifththrough sixth variations where the at least one grate may include aplurality of through holes and the cross-sectional area of the pluralityof through holes may range from about macroscopic to about microscopicto about nanoscopic in size.

An eighth variation may include a method that may include providing afirst part and a casting mold. The first part may include a body and bemade of a first composition. The body may define at least one throughhole within the first part. The first part may be positioned within themold and a molten material may be flowed into the mold and through theat least one through hole of the first part. The molten material may bemade of a second composition; the second composition may differ from thefirst composition. The molten material may be allowed to cool such thata second part is formed. The second part may form an interlockingmechanical bond with the first part via a portion of the second partextending through the at least one through hole of the first part.

A ninth variation may include a method as set forth in the eighthvariation wherein the cross-sectional area of the at least one throughhole may range from about macroscopic to about microscopic to aboutnanoscopic in size.

A tenth variation may include a method as set forth in the eighththrough ninth variations where the first composition of the first partmay be capable of chemically bonding to the second composition of thesecond part.

An eleventh variation may include a method as set forth in the eighththrough tenth variations where the composition of the first part may beincapable of chemically bonding to the composition of the second part.

A twelfth variation may include a method as set forth in the eighththrough eleventh variations where the first part may additionallyinclude at least one grate and where the at least one grate may bedisposed within the at least one through hole of the first portion. Thegrate portion may be constructed and arranged to further facilitate theinterlocking mechanical bond of the first portion and the secondportion.

A thirteenth variation may include method as set forth in the eighththrough twelfth variations where the first part may be a hard polymerand the second part may be a soft polymer.

A fourteenth variation may include a method as set forth in the eighththrough thirteenth variations where the at least one grate may include aplurality of through holes and the cross-sectional area of the pluralityof through holes may range from about macroscopic to about microscopicto about nanoscopic in size.

A fifteenth variation may include a method that may include providing amold. The mold may define a cavity. A first molten material may beinjection molded within the cavity and allowed to harden, therebyforming a first part. The first part may include a body and be made of afirst composition. The body may define at least one through hole withinthe first part. A second molten material may be injection molded withinthe cavity and may flow through the at least one through hole of thefirst part. The second molten material may be made of a secondcomposition and the second composition may differ from the firstcomposition. The second molten material may be allowed to cool such thata second part is formed. The second part may form an interlockingmechanical bond with the first part via a portion of the second partextending through the at least one through hole of the first part.

A sixteenth variation may include a method as set forth in the fifteenthvariation wherein the cross-sectional area of the at least one throughhole may range from about macroscopic to about microscopic to aboutnanoscopic in size.

A seventeenth variation may include a method as set forth in thefifteenth through sixteenth variations where the first composition ofthe first part may be capable of chemically bonding to the secondcomposition of the second part.

An eighteenth variation may include a method as set forth in thefifteenth through seventeenth variations where the composition of thefirst part may be incapable of chemically bonding to the composition ofthe second part.

A nineteenth variation may include a method as set forth in thefifteenth through eighteenth variations where the first part may be ahard polymer and the second part may be a soft polymer.

A twentieth variation may include a method as set forth in the fifteenththrough nineteenth variations where at least one grate may be providedwithin the cavity and the first molten material may be allowed to flowover the at least one grate, and where the first molten material may beallowed to harden, thereby encapsulating a portion of the at least onegrate and where a portion of the at least one grate remains exposedwithin the at least one through hole of the first portion. The at leastone grate may include a plurality of through holes and thecross-sectional area of the plurality of through holes may range fromabout macroscopic to about microscopic to about nanoscopic in size.

The above description of variations of the invention is merelydemonstrative in nature and, thus, variations thereof are not to beregarded as a departure from the spirit and scope of the inventionsdisclosed within this document.

1. A product comprising: a first portion comprising a molded firstcomposition and being constructed and arranged to define at least onethrough hole, wherein the first part comprises a body and a firstchemical composition, the body defining a first surface, a secondsurface, and at least one through hole between the first surface and thesecond surface; a second portion comprising a molded second compositionand being constructed and arranged to extend through the through hole ofthe first portion such that the first portion and the second portion arein an interlocking mechanical bond and so that the second part abutsboth the first surface and the second surface.
 2. A product as set forthin claim 1: wherein the cross-sectional area of the at least one throughhole ranges from about macroscopic to about nanoscopic in size.
 3. Aproduct as set forth in claim 1: wherein the first composition of thefirst portion is chemically bonded to the second composition of thesecond portion.
 4. A product as set forth in claim 1: wherein thecomposition of the first portion is not chemically bonded to thecomposition of the second portion.
 5. A product as set forth in claim 1:wherein the first portion further comprises at least one grate and wherethe at least one grate is disposed within the at least one through holeof the first portion; and wherein the grate portion is constructed andarranged to further facilitate the interlocking mechanical bond of thefirst portion and the second portion.
 6. A product as set forth in claim1: wherein the first portion comprises a hard polymer and the secondportion comprises a soft polymer.
 7. A product as set forth in claim 1:wherein the at least one grate comprises a plurality of through holesand the cross-sectional area of the plurality of through holes rangesfrom about macroscopic to about microscopic to about nanoscopic in size.8-20. (canceled)
 21. A product as set forth in claim 1 wherein thesecond part at least partially encloses the first part.